How to Achieve Inclusive Growth 1st Edition
https://ebookmass.com/product/how-to-achieve-inclusive-growth-1stedition-valerie-cerra/
ebookmass.com
Advanced Machining and Finishing
Editors
Kapil Gupta
Mechanical and Industrial Engineering Technology, University of Johannesburg, Johannesburg, South Africa
Alokesh Pramanik
Table of Contents
Cover image
Title page
Copyright
Contributors
Foreword
Preface
Part I. Advanced machining
Chapter 1. Advances in conventional machining processes for machinability enhancement of difficult-to-machine materials
Chapter 2. Advances in machining of particulate-reinforced metal matrix composites
Chapter 3. Gun drilling of difficult-to-machine materials
Chapter 4. Advancements in conventional machining: a case of vibration and heat-assisted machining of aerospace alloys
Chapter 5. Recent developments in spark erosion–based machining processes: A state of the art in downscaling of spark erosion based machining processes
Chapter 6. Developments in abrasive water jet machining process —from 1980 to 2020
Chapter 7. Advances in conventional and nonconventional highspeed machining
Chapter 8. Hybrid machining and finishing processes
Chapter 9. Relevance of micromachining in microfluidics and biomedical devices
Chapter 10. Advancements in electrochemical machining
Chapter 11. Machining of polymeric composite materials by water jet with abrasive: defectology and influence of cutting parameters
Chapter 12. Laser-based machining – an advanced manufacturing technique for precision cutting
Chapter 13. An insight on ultrasonic machining technology Part II. Advanced finishing
Chapter 14. Advances in burnishing technology
Chapter 15. Advanced thermal energy method for finishing precision parts
Chapter 16. Micro–nano surface texturing, characterization, and their impact on biointerfaces
Chapter 17. Fundamental understanding and latest developments in magnetic field assisted finishing processes
Chapter 18. Laser surface texturing as a finishing process for aerospace alloys
Index
Copyright
Elsevier
Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
Copyright © 2021 Elsevier Inc. All rights reserved.
No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website:
This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).
Notices
Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in
research methods, professional practices, or medical treatment may become necessary.
Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.
To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.
Library of Congress Cataloging-in-Publication Data
A catalog record for this book is available from the Library of Congress
British Library Cataloguing-in-Publication Data
A catalogue record for this book is available from the British Library
ISBN: 978-0-12-817452-4
For information on all Elsevier publications visit our website at https://www.elsevier.com/books-and-journals
Publisher: Matthew Deans
Acquisitions Editor: Brian Guerin
Editorial Project Manager: Mariana Henriques
Production Project Manager: Sojan P. Pazhayattil
Cover Designer: Victoria Pearson
Typeset by TNQ Technologies
Contributors
of Electrical Engineering, St. Joseph’s College of Engineering & Technology, Choondacherry, Kerala, India
of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India
of Mechanical Engineering, Manipal University Jaipur, Jaipur, Rajasthan, India of Engineering, University of Cadiz, Avda de la Universidad de Cádiz, Puerto Real, Spain
of Engineering, University of Cadiz, Avda de la Universidad de Cádiz, Puerto Real, Spain
Neeraj of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, Madhya Pradesh, India of Aerohydrodynamics, National Aerospace University “Kharkiv Aviation Institute,” Kharkiv, Ukraine
of Mechanical Engineering, Indian Institute of Technology
Palakkad, Palakkad, India
of Mechanical Engineering, National University of Singapore, Singapore
of Mechanical Engineering, Indian Institute of Technology
Guwahati, Guwahati, Assam, India
J. of Mechanical Engineering, University of Aveiro, Campus Santiago, Aveiro, Portugal
of Mechanics and Machine Elements, Technical University of Varna, Bulgaria, Varna
Vocational School, ESOGU, Eskişehir, Turkey
Muhammad of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, United States
Pramod of Mechanical and Industrial Engineering, Indian Institute of Technology, Roorkee, Uttarakhand, India
Engineering Department, Pandit Deendayal Petroleum University, Gandhinagar, Gujarat, India
of Mechanical Engineering and Machine Tools, Technical University of Varna, Bulgaria, Varna
A. of Mechanical Engineering, National University of Singapore, Singapore
Engineering Department, National Institute of Technology Calicut, Kozhikode, Kerala, India
Maan of Mechanical Engineering, National University of Singapore, Singapore
University of Technology, Auckland, New Zealand
RI Entities, Singapore Institute of Manufacturing Technology (SIMTech), Singapore
Md of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, United States
Engineering Department, National Institute of Technology Calicut, Kozhikode, Kerala, India
of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, India
Dennis Wee RI Entities, Singapore Institute of Manufacturing Technology (SIMTech), Singapore
Chandrakant of Mechanical Engineering, Indian Institute of Technology Ropar, Rupnagar, Punjab, India
Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Patna, Bihta, Bihar, India
of Mechanical Engineering, St. Joseph’s College of Engineering & Technology, Choondacherry, Kerala, India
Sergiy Plankovskyy
Department of Physics, O.M. Beketov National University of Urban Economy in Kharkiv, Kharkiv, Ukraine
Department of Aircraft Manufacturing Technology, National Aerospace University “Kharkiv Aviation Institute,” Kharkiv, Ukraine
University of Technology, Auckland, New Zealand
Stock Company “FED,” Kharkiv, Ukraine
Tej Pratap
Department of Mechanical Engineering, Motilal Nehru National Institute of Technology Allahabad, Prayagraj, Uttar Pradesh, India
Micro-fabrication Laboratory, Department of Mechanical Engineering, Indian Institute of Technology Patna, Bihta, Bihar, India
Ravi of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India
of Mechanical Engineering, Indian Institute of Technology (ISM) Dhanbad, Dhanbad, Jharkhand, India
of Mechanical and Manufacturing Engineering, Miami University, Oxford, OH, United States
of Engineering, University of Cadiz, Avda de la Universidad de Cádiz, Puerto Real, Spain
of Engineering, University of Cadiz, Avda de la Universidad de Cádiz, Puerto Real, Spain
of Mechanical Engineering, National University of Singapore, Singapore of Mechanical Engineering, Indian Institute of Technology Bombay, Mumbai, India of Aircraft Manufacturing Technology, National Aerospace University “Kharkiv Aviation Institute,” Kharkiv, Ukraine
S.L., Parque Científico Tecnológico, C/Inteligenccia, Jerez de la Frontera, Spain
of Mechanical Engineering, Indian Institute of Information Technology, Design and Manufacturing, Jabalpur, Madhya Pradesh, India
of Mechanical Engineering and Machine Tools, Technical University of Varna, Bulgaria, Varna
Engineering Department, Higher Colleges of Technology, Abu Dhabi, United Arab Emirates
Mehmet of Mechanical Engineering, ESOGU, Eskişehir, Turkey
Irene Del Sol of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cádiz, Cádiz, Spain
of Aircraft Manufacturing Technology, National Aerospace University “Kharkiv Aviation Institute,” Kharkiv, Ukraine
of Aircraft Manufacturing Technology, National Aerospace University “Kharkiv Aviation Institute,” Kharkiv, Ukraine
Eneko Ukar of Mechanical Engineering (UPV/EHU), Bilbao, Spain
Juan of Mechanical Engineering and Industrial Design, Faculty of Engineering, University of Cádiz, Cádiz, Spain
of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, Australia of Mechanical and Manufacturing Engineering, The University of New South Wales, Sydney, NSW, Australia
of Mechanics and Aerospace Engineering, Southern University of Science and Technology, Shenzhen, Guangdong, China
Foreword
Dear Readers,
This series of handbooks on advanced manufacturing covers four major areas, namely advanced machining and finishing, advanced welding and deforming, additive manufacturing, and sustainable manufacturing. The series aims to not only present the advancements in various manufacturing technologies, but also provide a fundamental and detailed understanding about them. It encompasses a wide range of manufacturing technologies with their mechanisms, working principles, salient features, applications, and research, development, and innovations in there. Fundamental research, latest developments, and case studies conducted by international experienced researchers, engineers, managers, and professors are mainly presented. Handbook 1 on advanced machining and finishing majorly covers advanced machining of difficult-to-machine materials; hybrid, high-speed, and micromachining; and burnishing, laser surface texturing, and advanced thermal-energy-based finishing processes. Handbook 2 on advanced welding and deforming covers ultrasonic welding, laser welding, and hybrid welding-type advanced joining processes and also describes advanced forming techniques such as microwave processing, equal channel angular pressing, and energy-assisted forming etc. Handbook 3 additive manufacturing sheds light on 3D
and 4D printing, rapid prototyping, laser-based additive manufacturing, advanced materials, and postprocessing in additive manufacturing. Handbook 4 on sustainable manufacturing presents advancements, results of experimental research, and case studies on sustainability interventions in production and industrial technologies.
We hope that this series of handbooks would be a good source of knowledge and encourage researchers and scientists to conduct research, developments, and innovations to establish these fields further.
J Paulo Davim and Kapil Gupta
Preface
Process productivity and part quality are two major groups of machinability indicators in case of machining and finishing processes. Conventional approaches in machining and finishing merely fulfill the current mass production and precision quality requirements. To overcome the limitations and address the challenges, technological advancements have been in place for both machining and finishing processes. Developments in machine tool structure and tooling, process hybridization, microtechnology and miniaturization, and utilizing unique energy sources and process principles are some of the technological advancements that have been found successful to a large extend to fulfill machining and finishing requirements.
This handbook covers such technological advancements in case of various important machining and finishing processes. Working principle, mechanism, process parameters, technical details, salient features, case studies, and manufacturing of micro and precision parts from a wide range of materials, etc., are majorly focused in this handbook.
The latest research in this area and possible avenues of future research are also highlighted to encourage the researchers.
The handbook consists of a total of 18 selected chapters on advances in machining and finishing processes. It starts with Chapter 1 that sheds light on recent advances in conventional machining processes for machinability enhancement of difficult-tomachine (DTM) materials. Chapter 2 specifically provides some insights on advances in machining of particulate-reinforced metal matrix composites. Advanced gun drilling of DTM materials is focused in Chapter Chapter 4 describes a case of vibration and heat-assisted machining of aerospace alloys. Recent developments in spark erosion-based machining processes are detailed in Chapter Technological developments in abrasive water jet machining process are covered in Chapter Advances in high-speed machining, both conventional and nonconventional type, are discussed in Chapter Chapter 8 details advanced hybrid machining and finishing processes for various application requirements. Chapter 9 presents unique micromachining process for manufacturing of microfluidics and biomedical devices. Some recent advancements in electrochemical machining are described in Chapter Abrasive water jet machining of polymeric composite materials with a special focus on defectology and influence of process parameters is in Chapter Chapter 12 highlights precision cutting of engineered parts by laser beam machining. Chapter 13 provides an insight on ultrasonic machining technology. Advances in burnishing technology are presented in Chapter A unique and advanced thermal-energy-based finishing method for manufacturing of precision parts is discussed in Chapter A wide range of micro–nano surface texturing techniques and their effects on biointerfaces are described in Chapter Chapter 17 provides basic knowledge and advancements in magnetic-field-assisted finishing processes. Finally, Chapter 18 sheds light on finishing of aerospace alloys using laser surface texturing process.
We hope that this handbook will be a good source of knowledge and information for researchers, engineers, technical experts, and specialists working in the area of advanced machining and finishing and materials engineering. We sincerely acknowledge Elsevier Inc. for this opportunity and their professional support. Finally, we would like to thank all the contributors for their time and efforts.
January 2021
Gupta and Alokesh Pramanik
Kapil
Part I
Advanced machining Outline
Chapter 1. Advances in conventional machining processes for machinability enhancement of difficult-to-machine materials
Chapter 2. Advances in machining of particulate-reinforced metal matrix composites
Chapter 3. Gun drilling of difficult-to-machine materials
Chapter 4. Advancements in conventional machining: a case of vibration and heat-assisted machining of aerospace alloys
Chapter 5. Recent developments in spark erosion–based machining processes
Chapter 6. Developments in abrasive water jet machining process —from 1980 to 2020
Chapter 7. Advances in conventional and nonconventional highspeed machining
Chapter 8. Hybrid machining and finishing processes
Chapter 9. Relevance of micromachining in microfluidics and biomedical devices
Chapter 10. Advancements in electrochemical machining
Chapter 11. Machining of polymeric composite materials by water jet with abrasive: defectology and influence of cutting parameters
Chapter 12. Laser-based machining – an advanced manufacturing technique for precision cutting
Chapter 13. An insight on ultrasonic machining technology
Chapter 1: Advances in conventional machining processes for machinability enhancement of difficult-to-machine materials
Ashwin Polishetty, and University of Technology, Auckland, New Zealand
Abstract
During last decade, manufacturing sector has undergone a rapid change with the advent and adaptation of new technologies in a commercial environment. Modern machining, additive and sustainable manufacturing, and process optimization are the latest trends. This chapter discusses the modern machining strategies required for successful processing of difficult-to-machine materials. Some of the materials under consideration are selective laser melted (SLM) titanium Ti6Al4V and super austenitic stainless steel. The machinability of the materials has been evaluated considering the tool wear, cutting force, and surface finish type indicators.
Keywords
Machinability; Manufacturing; Productivity; Stainless steel; Surface finish; Titanium alloys; Tool wear
1. Introduction
The ability of a material to produce acceptable outcomes with respect to the tool wear, Metal Removal Rate (MRR), surface integrity, and power consumption when machined is called machinability. Machinability is often a qualitative than a quantitative assessment of the process. Evaluating machinability is considered important especially for materials that are challenging to machine Machinability factors or indicators are tool wear, MRR, dimensional accuracy, surface integrity, and power or energy consumption, and so on. Considering the earlier research studies on machining, there is high percentage of products manufactured using machining. It is highly advantageous to find ways for successful machining and processing of materials Some of the common problems encountered in machining are work surface deterioration and irregularity, rapid tool wear, lower MRR, and out-of-tolerance parts This chapter is an attempt to identify and plug the research gaps by analyzing the existing literature and future requirements necessary for the growth and sustainability of the machinability research related to the selected materials i.e., Selective Laser Melted (SLM) titanium Ti6Al4V, and Super Austenitic Stainless Steel (SASS).
1.1.
This section critically reviews the literature on machinability characteristics of SLM titanium Ti6Al4V, to identify the research gaps. Titanium components are fabricated conventionally using different manufacturing and forming techniques. Poor machinability of titanium alloys is a major concern to be addressed for use in various engineering applications The likely reasons for poor machinability of titanium alloys are poor thermal conductivity, low modulus of elasticity, dynamic shear strength, high chemical reactivity, and high hot hardness. Machining titanium alloys often
Selective Laser Melted (SLM) titanium Ti6Al4V
